Currently reading: New Caterham factory boosts capacity by 50%

CEO says being able to build 750 cars a year is “game-changing” and allows expansion into new markets

Caterham will no longer need to “turn customers away”, CEO Bob Laishley has told Autocar, after opening a multi-million-pound new base that will boost its production capacity by 50%.

Labelled as a “game-changer” that has “transformed the business in every way”, the headquarters is located just down the road from the firm’s former factory in Dartford, Kent.

Caterham can now build up to 750 Sevens annually, thanks to 33 new build stations at the new facility, up from 22 at the old one.

“Before, we would have orders for 600 cars but only be able to build 500, so we would have to turn customers away,” said Laishley.

“Increasing production to 750 has also allowed us to explore markets we have always suppressed because of capacity, such as the USA.”

The close proximity to the former site was key to retaining the firm’s 130 staff, especially its mechanics and engineers.

As well as a new factory floor, the 54,000sq ft site – which was funded by Caterham's Japanese owner, VT Holdings, and took nine months to fit out – houses the brand’s motorsport and commercial operations. 

Bringing all of those under one roof means the brand “feels more connected than ever”, said Laishley. “It makes us a more efficient, streamlined business”, he added.

What’s more, the quality of the new site was summed up by Laishley as he recalled visiting the former factory for the final time: “Were we really working here?”

VT Holdings CEO Kazuho Takahashi said: “We are thrilled. This modern facility exemplifies VT Holdings' unwavering dedication and support for the iconic British sports car brand, Caterham. 

"From this new location, we will continue to take pride in delivering increasingly high-quality vehicles to our customers worldwide.”

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The production version of the Caterham Project V electric coupé concept won't be built at Dartford, though, instead handled by a third party.

Q&A: Bob Laishley, CEO, Caterham

Can you push beyond 750 units?

“All our cars are hand-built. When one person builds one car, you can’t really expand that, as it means that person is just working more. Expanding to more than 1000 cars a year also brings homologation issues [regarding type approval laws].”

Have you decided where you will build the Project V?

“It has always been our preference to build in the UK. But I've always said the UK’s economic circumstances need to be right, which is why we are also looking abroad. I don't want that to be perceived as a threat [to the UK], but when you're looking to make 2000 cars a year, only a few firms can do that, and only a few of those are in the UK.”

Does the higher output mean you have funding for future projects?

“It does, but firstly we need that additional revenue to back the significant investment in the factory. After that we can start to look at the future.”

Will Rimell

Will Rimell
Title: News editor

Will is Autocar's news editor.​ His focus is on setting Autocar's news agenda, interviewing top executives, reporting from car launches, and unearthing exclusives.

As part of his role, he also manages Autocar Business – the brand's B2B platform – and Haymarket's aftermarket publication CAT.

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